Engine: Description and Operation

Engine





The vehicle range is fitted with the "New Generation 2.0L Zetec-E engine". The most significant features are:
^ Hydraulic engine mountings
^ 16 valve DOHC
^ Pull flow oil filter
^ Aluminum alloy cylinder head
^ Cast iron block
^ High temperature resistant coating on exhaust valves
^ Valve train with mechanical tappets
^ Modified timing belt guide
^ Aluminium timing belt cover with integral engine mounting function to reduce noise, vibration and harshness (NVH)
^ Aluminium crankcase reinforcement and flat oil pan reduce NVH
^ Generator with check-back function for generator load

The changes made are:
^ close coupled tri-metal catalytic converter
^ EGR system
^ Adjustable valve tappets
^ use of a cylinder head temperature (CHT) sensor in place of an engine coolant temperature (ECT) sensor.










VIN Derivative location on the cylinder block


Zetec-E Engine Design

Timing Belt Center Cover/Engine Front Mounting Bracket:

Central timing belt cover/Front engine mounting
The new timing belt cover is further reinforced by a vertical support. The central timing belt cover and the front engine mounting have to be removed to fit a new timing belt.














Valve Train
The exhaust valve springs are marked blue whilst the inlet valve springs are marked red. The valve clearance can be adjusted by exchanging the valve tappets.
Precision is required when adjusting the valve clearance in order to avoid repeated removal and reinstallation of the camshafts.

Mechanical bucket tappet
The level of wear is so minimal that initial checking and adjustment of the valve clearance is not necessary until 150,000 km (90,000 miles).









Drive belt
^ A new timing belt must be installed after 150,000 km (90,000 miles) or after 10 years.
^ A new timing belt must always be installed after repair work in which it was removed.










Timing Belt Tensioner

CAUTION: Only tension the timing belt by turning in a counterclockwise direction.

An automatic timing belt tensioner ensures that the belt has the correct tension. When a new belt is fitted, the tensioner is moved into the base setting (arrowhead (3) and marker (2) are in line). This base setting is taken up by one of the cams (4). Another (spring-loaded) cam ensures that the belt is kept at the correct tension when the engine is running. The belt tensioner moves up to 30 degrees from its center position in each direction.

NOTE: Do not re-tighten the belt since there is a risk of exceeding the permitted working range in one of the directions. The belt tensioner base setting only applies in the case of new timing belts. Re-tightening of the belt can cause it to rip or flutter.

It is no longer possible to check the base setting once the adjustment tools and pin have been removed (the spring forces of the valve train are exerted on the belt and change the position of the belt tensioner).














Intake Manifold
The new Zetec-E engines are fitted with an intake manifold made of glass fiber reinforced plastic. The ducts in the intake manifold are arranged to ensure that the intake distance is the same for each cylinder.









Crankshaft
The crankshaft is housed in five bearings and has a counterweight for each cylinder. The central main bearing has two thrust half shells which axially guide the crankshaft and set the end float.

Connecting (ISC) rod bearings
The connecting rods are numbered one to four starting the timing belt end. It is practically impossible to mix-up the connecting rod bearing caps and connecting rods since the connecting rod bearing caps are broken away from the connecting rod during production. The fracture profile of a connecting rod bearing cap therefore only fits one of the connecting rods. Crankcase Reinforcement Lower crankcase view of Crankcase Reinforcements The crankcase reinforcements are designed to damp engine vibrations. This leads to a further reduction in interior noise levels. The crankcase reinforcements are sealed against the cylinder block by means of a flat carrier gasket.

View Of Lower Crankcase:

Crankcase Reinforcement
The crankcase reinforcement spacers are needed to even out any excessive gap between the transmission and the oil pan, The unit is closed off at the bottom by a drawn sheet metal oil pan which is directly fixed to the crankcase reinforcements. A 3 mm wide bead of sealer ensures that the unit is leakproof.





Crankcase Reinforcements Spacers
The crankcase reinforcement spacers are needed to even out any excessive gap between the transmission and the crankcase reinforcements.






Oil Pan
The unit is closed off at the bottom by a drawn sheet metal oil pan which is directly fixed to the crankcase reinforcements. A 3 mm wide bead of sealer ensures that the unit leak proof.

Engine Control-Powertrain Control Module (PCM)
The PCM controls the Zetec-E engine. To enable it to do this, the PCM requires comprehensive information regarding the current operating state of the engine. The PCM obtains this information by means of numerous sensors.
^ The PCM controls:
- the fully electronic (EI) ignition system
- the sequential electronic fuel injection (SEFI)
- the air-conditioning system in conjunction with the cooling system.